Electric Drive Module Layout for Compact Torque Vectoring

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Solution Overview

Problem

Conventional drive module assemblies face challenges in achieving high efficiency, compact size, and low weight while integrating parking locks, torque vectoring, and limited slip capabilities in hybrid and battery electric vehicles.

Innovation Solution

A drive module assembly design featuring a housing with an electric machine, rotor, stator, input and output shafts, differential, gearset, clutch, and park lock, where the differential receives rotational torque from the electric machine and transmits it to input and output shafts, allowing for a compact design with reduced shaft and bearing diameters, and incorporating a gearset and clutch for torque vectoring and parking lock functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the drive module assembly is made more compact to reduce vehicle space requirements, then the vehicle's space utilization is improved, but integrating parking locks and torque vectoring capabilities becomes more difficult

Engineering Contradiction:

Improvedrive module assembly volumeVSAvoidintegration of parking lock and torque vectoring

Core Design Contradiction:

Volume of moving objectVSAdaptability or versatility

Solution Approach 1:

The patent combines the parking lock mechanism and torque vectoring differential into a single integrated assembly that shares common components. The parking lock is integrated with the differential case, and the torque vectoring capability is achieved through a clutch mechanism that works within the same housing, merging multiple functions into one compact unit.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The differential assembly serves multiple functions simultaneously: it provides torque distribution to wheels, enables torque vectoring through the clutch mechanism, and incorporates parking lock capability. This multi-functionality allows the compact assembly to deliver rotational torque while also providing vehicle stopping capability and differential lock functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Weight of moving object

If the drive module assembly weight is reduced to improve vehicle efficiency, then the vehicle's energy consumption is improved, but the structural strength and torque capacity may be compromised

Engineering Contradiction:

Improvedrive module assembly weightVSAvoidstructural strength and torque capacity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent optimizes the dimensional parameters of shafts and bearings to achieve the lightest possible weights while maintaining sufficient strength. The shaft diameters and bearing sizes are carefully selected to provide the minimum required structural strength for the intended torque capacity, eliminating excess material weight.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The housing and structural components are designed to utilize material properties efficiently, potentially employing composite or optimized alloy materials that provide high strength-to-weight ratios, allowing the assembly to maintain structural integrity while minimizing weight.

Inventive Principle:

Principle #40Composite materials

3Length of moving object

If shaft and bearing diameters are reduced to achieve a more compact design, then the drive module assembly size is reduced, but the torque transmission capacity and rotational speed limits are affected

Engineering Contradiction:

Improveshaft and bearing dimensionsVSAvoidtorque transmission capacity

Core Design Contradiction:

Length of moving objectVSPower

Solution Approach 1:

The shaft and bearing dimensions are optimized to the minimum sizes that can handle the required torque and speed loads. The patent carefully selects shaft diameters and bearing inner/outer dimensions to achieve compact sizes while maintaining adequate power transmission capability through proper material selection and dimensional optimization.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The clutch mechanism provides torque vectoring capability that can compensate for reduced shaft and bearing capacity by selectively applying torque to individual wheels, allowing smaller diameter components to achieve the required overall power transmission through intelligent torque distribution.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design achieves a compact and efficient drive module assembly with improved performance, enabling higher gear ratios, faster shaft rotation, and integrated torque vectoring and parking lock capabilities, while maintaining a lightweight structure.

Implementation Method 1

an electric machine configured to deliver rotational torque to wheels of a vehicle

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12398789B2Drive module assembly

Publication Date: 2025.08.26 BORGWARNER INC

AI summary

A drive module assembly for use in a vehicle includes a housing defining a housing interior and an electric machine. The electric machine includes a rotor and a stator. The drive module assembly includes a first input shaft, a second input shaft, a first output shaft, a second output shaft, and a differential disposed downstream of at least the rotor. The drive module assembly also includes a gearset, a clutch, and a park lock. The gearset, the clutch, and the park lock are disposed downstream of the differential such that the gearset and the clutch are configured receive rotational torque from the differential through the first and second output shafts.